Active Sterilization Zone for Container Filling

ABSTRACT

An apparatus for sterile filling of beverage containers has a first module and a second module. The first module rinses and sterilizes empty containers and delivers the sterilized containers to the second module. The second module fills and caps the containers with beverage product at ambient temperature in an active sterilization zone utilizing an e-beam sterilization unit.

RELATED APPLICATIONS

This application claims priority to and the benefit of and is acontinuation-in-part of U.S. Application No. 60/949,149 filed on Jul.11, 2007 entitled “Apparatus and Method for Sterile Filling of BeverageContainers,” which is incorporated herein by reference and made a parthereof.

TECHNICAL FIELD

An exemplary embodiment disclosed herein relates to sterile filling ofbeverage containers, and in particular, an in-line filling apparatusthat creates an active sterilization zone in a confined hygienicenvironment (“CHE”) for filling and closing containers.

BACKGROUND OF THE INVENTION

Various types of beverages or products are stored in different types ofcontainers for eventual consumption by consumers. Beverages and otherproducts are typically filled in containers such as thermoplastic orglass liquid containers in an automated filling process. The product,the container, and container closure, such as a cap, must all besterilized, or free from microorganisms, to provide the consumer with asafe product that has the respective quality attributes expected by theconsumer.

Typically containers can be filled with beverages in either a“cold-fill” process or a “hot-fill” process. FIG. 1 discloses a blockdiagram of one type of container filling and capping apparatus,typically used in a cold-fill process. FIG. 2 shows a process flowdiagram of a typical aseptic cold-fill process. In cold-fillapplications, the beverage product is heated to an elevated temperaturefor a specific time interval to kill any microorganisms (referred to aspasteurization) and is then cooled to generally ambient temperatures.Pre-sterilized containers are then filled with the cooled sterilizedproduct in a filler 11 and the containers are capped with pre-sterilizedcaps by a capper 13.

In order to ensure a safe product for the consumer, the filling area ina cold-fill system must never be contaminated. Operators must wearhygienic suits, and anything that enters into the aseptic chamber mustbe sterilized. If there is any suspicion that a contaminant has enteredthe aseptic environment, the process must be shutdown, and the systemmust be sterilized. Cleaning a contaminated aseptic environment back toaseptic standards, however, is time consuming. All cleaning andsterilization of the associated equipment must occur during a productionstoppage, therefore limiting production capability. These factors makeaseptic filling lines operationally cumbersome.

In the hot-fill process, the hot beverage itself is used to sterilizethe containers at the filling stage. As depicted in FIG. 3, in hot-fillapplications, empty containers are initially rinsed and then filled by afiller 11 with a beverage that has been heated to an elevatedtemperature for sterilization. The hot beverage is not hot enough toaffect the container functionality or to deform the container. In aconcurrent path, caps are provided and placed on the containersimmediately after filling by a capper 13. Once capped, the containersare inverted, such that the caps and the headspaces of the containersare sterilized utilizing the heated product in a cap sterilizer 15. Thecapped containers are then allowed to cool for further processing in acooling tunnel 17.

In such hot-fill processes, the containers used must have a robust wallconstruction that can resist the high temperature of the hot beverage.The overall process requires the container to be able to withstandinversion of the container by grippers, and, therefore, requires thecontainers to be of a heavier weight thereby increasing material costs.In addition, as the beverage and container are cooled, a vacuum isexperienced inside the capped container due to material shrinkage.Because of this vacuum, the container must have vacuum panels to absorbthe shrinkage. Finally, since the beverage product must be such that theliquid remains hot for sufficient time to sterilize the container andcaps, and then cooled, there is significant energy lost to theenvironment with the hot-fill process. These factors contribute toconsiderable material and operational costs of filling containers in ahot-fill process. Similar to the cold-fill process, cleaning of thehot-fill filler/capper equipment requires a stoppage of production,limiting the production capability.

An exemplary embodiment is provided to solve the problems discussedabove and other problems, such as limited container design, and toprovide advantages and aspects not provided by prior systems of thistype. Nevertheless, the exemplary embodiments disclosed can be used tofill the containers described above. Additionally an exemplaryembodiment is provided to provide more design freedom than prior systemsof this type. A full discussion of the features and advantages of thedisclosed exemplary embodiments is deferred to the following detaileddescription.

SUMMARY OF THE INVENTION

An exemplary embodiment of the invention provides a system and methodfor sterile filling of containers. This system provides an activesterilization zone in a CHE and includes a first module that may includea container rinser and a container sterilization unit, and a secondmodule that may include a filler assembly and a capper assembly andfurther having a sterilization unit associated therewith.

According to one exemplary embodiment, the containers are directed viaan in-line conveyor assembly through the first module and the secondmodule. Once the containers are de-palletized and directed into thefirst module via the conveyor assembly, the containers pass through awaterless rinsing station and then are directed to a containersterilization unit having a high-powered electron beam emitter whereinthe containers are initially sterilized. The containers are thenconveyed to the second module having a filler assembly wherein thecontainers are filled with a beverage or product under asepticconditions. The containers are then transferred to the capper assembly.A second sterilization unit is operably associated with the fillerassembly and capper assembly in the second module. In one exemplaryembodiment, the sterilization unit has low-powered e-beam emitters thatprovide a sterile environment for the filling and capping of productssuch as beverages, liquids, or foods, etc. The sterilization unit andother associated structures and systems provide the active sterilizationzone in the CHE in which the containers travel. The sterilizationtechnique disclosed herein can be used to sterilize any type ofcontainer whether the container is adapted to receive, for example,filtered, preserved, or pasteurized product. The product is maintainedat a generally ambient temperature. The sterile filled and cappedcontainers are then directed for further packaging.

A apparatus and method for sterilizing components of a transfer wheel isdisclosed. The transfer wheel is configured to transfer open filledcontainers from a filler assembly to a capping assembly and has an airmanagement system. The system has a conduit for the supply of air in adownward direction past the containers on the transfer wheel. Theconduit has an inlet duct adapted to be in communication with the supplyof air and has an outlet manifold having an opening and the supply ofair is directed through the opening. The outlet manifold has a curvedshape, is positioned on a portion of the transfer wheel, has an openbottom section, has a generally horizontal top surface, and has a pairof spaced sidewalls depending from the top surface. A mesh screen ispositioned in the opening proximate the top surface. The outlet manifoldhas a generally inverted U-shaped cross-section.

An apparatus and method for receiving a sterile container and deliveringthe sterile container to a filler assembly is disclosed. The apparatushas a housing consisting of a container inlet opening, a containeroutlet opening, and an air inlet opening. A shroud is positioned aroundthe container inlet opening and has an open bottom end. An intakeconveyor is positioned in the housing and is adapted to receive thesterile container through the container inlet opening and pass thesterile container to the container outlet opening. An air source is incommunication with the air inlet opening, and the housing receives theair, and the air passes from the open bottom end. The air inlet openingis positioned on the ceiling of the housing. The filtered air sourcepressurizes the housing and can be ULPA/HEPA filtered air. The intakeconveyor has an intake wheel consisting of a gripper, and the gripper isadapted to grip a container delivered from a container sterilizer andpass the container to the container outlet opening. The intake conveyoralso has a first intake wheel operably associated with a second intakewheel, and the first intake wheel is adapted to receive the containerfrom a container sterilizer and to pass the container to the secondintake wheel. The second intake wheel is adapted to pass the containerto the container outlet opening. The housing has an access door and acontainer reject mechanism. Unacceptable containers are removed from theconveyor and can be accessed through the access door. Additionally anair cylinder having one end connected to the housing and another endconnected to the access door is provided. The air cylinder is operableto open and close the access door. The housing floor is slanted towardsthe access door to provide a ramped surface for the unacceptablecontainers.

Other features and advantages of the invention will be apparent from thefollowing specification taken in conjunction with the followingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way ofexample, with reference to the accompanying drawings in which:

FIG. 1 is a prior art schematic diagram of a container filling process;

FIG. 2 is a schematic diagram of a conventional aseptic cold-fillcontainer filling process;

FIG. 3 is a schematic diagram of a conventional hot-fill containerfilling process;

FIG. 4 is a block diagram of an active sterilization ambient-fillprocess according to an exemplary embodiment;

FIG. 5 is a schematic diagram of the active sterilization ambient-fillsystem/process according to an exemplary embodiment;

FIG. 6 is a schematic diagram of the active sterilization ambient-fillsystem/process according to an exemplary embodiment and showing a firstmodule and a second module;

FIG. 7 is a schematic view of a container in an electron field producedby an e-beam emitter/sterilizer;

FIG. 8 is a schematic view of two containers in an electron fieldshowing container gripping and container inversion;

FIG. 9 is a schematic diagram of an e-beam emitter generating anelectronic field and a container passing therethrough;

FIG. 10 is a schematic plan view of a second module of the system of anexemplary embodiment;

FIG. 11 and 11 a are a partial perspective views of the second module ofthe system of an exemplary embodiment;

FIG. 12 is a perspective view of an isolator assembly of the secondmodule of the system of an exemplary embodiment;

FIG. 13 is a partial perspective view of the isolator assembly;

FIG. 14 is a schematic partial cross-sectional view of an interface areabetween the first module and second module of the system of an exemplaryembodiment;

FIG. 15 is a partial plan view of the second module and showing a fillerassembly;

FIG. 15 a is a partial cross-sectional view of filler grippers;

FIG. 16 is a partial perspective view of the filler assembly;

FIG. 17 is an partial exploded view of the filler assembly;

FIG. 18 is partial elevation view of an inlet manifold of an airmanagement system of the filler wheel;

FIG. 19 is a plan view of the inlet manifold of FIG. 18;

FIGS. 20-22 are partial cross-sectional views of the inlet manifold;

FIG. 23 is a partial cross-sectional view of the filler assembly andshowing an air flow path of the filler wheel air management system;

FIG. 24 is a schematic view of an air flow around a container;

FIG. 25 is a partial perspective view of a transfer mechanism of thesecond module;

FIG. 26 is a partial cross-sectional view showing air flow of a transfermechanism air management system;

FIG. 27 is a schematic view of downward air flow around the container;

FIG. 28 is a partial plan view showing a capper assembly of the secondmodule;

FIG. 29 is another view of the capper assembly of the second module;

FIGS. 30-32 are partial perspective views showing the capper assembly ofthe second module;

FIG. 33 is a partial cross-sectional view showing the capper assembly ofthe second module;

FIG. 34 is another partial perspective view of the capper assembly ofthe second module;

FIG. 35 is a schematic view of e-beam emitters associated with thecapper assembly;

FIG. 36 is a schematic view of an environment control system associatedwith the first module and second module of the system of the presentinvention;

FIGS. 37-40 are schematic plan views of the second module showingoperation of the second module;

FIG. 41 is a perspective view of a filler valve;

FIG. 42 is a partial cross-sectional view of the filler assembly;

FIGS. 43-49 are schematic plan views of an alternative embodiment of thesecond module of the system of the present invention; and

FIGS. 50-53 disclose additional views of the alternative embodiment ofthe second module of the system of the present invention.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many differentforms, there are shown in the drawings and will herein be described indetail exemplary embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated.

Referring now to the FIGS., and initially to FIGS. 4-6, there is shownan exemplary embodiment of an apparatus for sterile filling ofcontainers, generally designated with the reference numeral 10. In oneexemplary embodiment, the containers are beverage containers, althoughthe system 10 can be used in various other container applicationsrequiring sterile filling and closing. The system 10 generally includesa first module, or station 12 and a second module or station 14. Thefirst station 12 and the second station 14 have certain associatedstructures 16, as explained in greater detail below, that cooperativelydefine a confined hygienic environment (“CHE”) 18. As explained ingreater detail below, the CHE 18 can take various forms among thedifferent exemplary embodiments disclosed herein. For example, in oneexemplary embodiment, the CHE 18 may be operably associated with thesecond module 14. An in-line conveyor assembly 20 is utilized as part ofthe system 10 to transport a plurality of containers C through the firstmodule or station 12 and the second module or station 14 as explained ingreater detail below.

Referring to FIG. 4, the first module 12 generally includes ade-palletizer 22, a waterless rinser 30 and a container sterilizer 32.The second module 14 generally includes a filler assembly 46 and acapper assembly 48. In a further exemplary embodiment (depictedschematically in FIG. 10), the second module 14 may further include ane-beam sterilization unit 50, an isolator assembly 52, the fillerassembly 46, a transfer mechanism 54, the capper assembly 48, and anenvironment control system 56. As shown in FIG. 4 and discussed furtherbelow, the capper assembly 48 may utilize e-beam sterilization as partof the e-beam sterilization unit 50, however, other sterilizationmethods may also be employed for the capper assembly including steam,external irradiation and chemical treatment as shown in FIG. 4. FIG. 4further shows that the product to be injected into the containers C mayproceed through batching, a thermal process and to a filler supply tankprior to being delivered to the filler assembly 46. FIG. 5 shows anadditional schematic view of the first module 12 and the second module14 and also shows additional detail regarding the batching process forthe beverage product to be injected into the plurality of containers C.The general structures of the first module 12 and the second module 14will first be described followed by a description of the operation ofthe first and second modules 12, 14.

Conveyor Assembly

As further shown schematically in FIGS. 4-6, the conveyor assembly 20,is an in-line system capable of transporting a plurality of containersin an automated fashion. The conveyor assembly 20, has conventionalstructure known in the art and includes structures for general transportas well as gripping structures for moving the containers through thesystem 10, via generally linear and arcuate paths as necessary. Inparticular, the conveyor assembly 20, may transport the containers C viathe container neck. The conveyor assembly 20 may have a plurality ofindividual conveyors operably connected to one another to transportcontainers from the de-palletizer station, designated 22 in FIG. 4,through the system 10, and to further packaging mechanisms, designated24 in FIG. 4, as desired. It is understood that other components of thefirst module 12 and the second module 14 may also form a portion of theconveyor assembly 20 such as the various wheels used to transport thecontainers C through the system 10. In one exemplary embodiment, manyportions of the conveyor assembly 20 are rotary-type conveyors. It isunderstood that other types of conveyors can be employed such asconveyors that transport containers in a linear fashion or indexingarrangement. Alternate conveyor assemblies could also transportcontainers C via a base of the containers C as opposed to a neckportion.

First Module

As discussed, the first module 12 includes the de-palletizer 22, thewaterless rinser 30 and the container sterilizer 32. Empty containers Care typically delivered to the system 10 on pallets. The de-palletizer22 is a known structure used to remove the empty containers C frompallets and to the conveyor assembly 20. As further shown in FIG. 5, thewaterless rinser 30 may include a plurality of air nozzles 31 arrangedin series fashion. The waterless rinsing station 30 receives emptycontainers C from the conveyor assembly 20 and initially rinses thecontainers C to remove bio-load and foreign matter. The waterless rinser30 is not considered to be part of the CHE 18 but is helpful to helpprevent foreign matter from entering into the CHE 18. As can beappreciated from FIGS. 5 and 6, the conveyor assembly 20 then transportsthe containers to the container sterilizer 32.

Container Sterilizer

In one exemplary embodiment, the container sterilizer 32 can use e-beamemitters 33 as an electron source to sterilize the containers C. Anyknown method, however, can be used to sterilize the containers C. Thee-beam container sterilizer 32 can include a high-powered electron beamemitter 33, shown in FIGS. 6-9. The container sterilizer 32 accommodatesportions of the conveyor assembly 20, for in-line sterilization of thecontainers C. FIGS. 7-9 schematically show portions of the containersterilizer 32 wherein the e-beam emitter 33 produces an active sterileelectron field 36 or e-beam field 36.

Once inside the container sterilizer 32, the containers C can be grippedby the neck of the container C and conveyed through a field of electronbeams emitted by the e-beam emitter 33 that form the active sterilefield 36. The container C may be inverted and rotated for a second passthrough the electron field 36 so that all sides of the container C areassured to pass through the sterile field of electron beams 36 as shownin FIGS. 7 and 9. This insures sterilization of all sides of thecontainer C and any and all cold spots around the finish and bottom ofthe container C. The sterile field 36 prevents reproduction, stopsfurther multiplication, and ends growth of any remaining bio-load.Preventing reproduction is equivalent to killing the organism. Once thesterilizer 32 sterilizes the containers C, an air purge is provided toremove ozone created inside the container C. The air is exhausted fromthe module and treated prior to release into the atmosphere. Thecontainer sterilizer 32 produces, via the e-beam emitter 33, the activesterile field 36 that encompasses the conveyor pathway in which thecontainer C travels.

E-Beam Generator in Container Sterilizer

FIG. 9 shows a schematic view of one type of electron beam emitter 33.In the electron beam emitter 33, electrons are transferred from afilament 60. The filament 60 is housed in a vacuum chamber 64, foraccelerating the electrons. A titanium window 62 is provided thatseparates the atmosphere 66 and the vacuum chamber 64. The electrons areaccelerated through the window 62, and thereby create the active sterileelectron field 36, which extends a suitable distance and covers asuitable area to sterilize the containers C. In one exemplaryembodiment, the e-beam emitter 33 is designed to provide a radiationdose of approximately 10-15 kGy to all surfaces of each container C,thereby achieving about a 6 log count reduction (“LCR”) of microbes onthe container surfaces. Such emitters 33 may be considered high-energye-beam emitters. The beams, however, can be generated by a suitablee-beam emitter having such energy capabilities. Such a unit is capableof generating electron beams that are of sufficient strength tosterilize the interior and exterior of a container.

The containers C are then transported out of the container sterilizer 32and to the second module 14. The container sterilizer 32 thus prepares asterile container C to be delivered to the second module 14 for fillingwith a product in an active sterilization zone in the CHE 18.

As discussed above, in one exemplary embodiment, the containersterilizer 32 utilizes a high energy e-beam emitter for sterilization.It is understood that the container sterilizer 32 in the first module 12can utilize other forms of sterilization, for example, irradiation,chemical, or heat/temperature sterilization. Thus, other sterilizingstructures and processes can be used to provide a sterile container C tothe second module 14.

Second Module 14

After sterilization of the containers C in the first module 12, thecontainers C are delivered to the second module 14 for furtherprocessing. As discussed, in the second module 14, the containers C arefilled with product in an active sterilization zone in the CHE 18,capped and delivered for further packaging. As discussed, in oneexemplary embodiment as shown in FIGS. 10 and 11, the second module 14generally includes the e-beam sterilization unit 50, the isolatorassembly 52, the filler assembly 46, the transfer mechanism 54, thecapper assembly 48 and the environment control system 56. Thesecomponents will now be described in greater detail. Portions of theconveyor assembly 20 assist in moving the containers C through thesecond module 14.

E-Beam Sterilization Unit

The e-beam sterilization unit 50 includes a plurality of e-beam emittersplaced at certain positions and areas within container travel zoneswithin the second module 14 such that only critical machine surfaces,components, and air immediately surrounding the components are subjectedto the e-beams and not the beverage product itself. The e-beamsterilization unit 50 forms part of the CHE 18 of the second module 14.In an exemplary embodiment, the e-beam emitters are low-energy e-beamemitters. In a particular embodiment, the e-beam emitters are 150 kVmodels. It is understood that other suitable e-beams emitters can beused. The e-beam sterilization unit 50 generally includes a filler wheelsterilization unit 70, a transfer mechanism sterilization unit 72, and acapper assembly sterilization unit 74. In one exemplary embodiment, thee-beam emitters have an outlet window 3 in. by 10 in. in size althoughthis size can vary as desired. The e-beam emitters are typically mountedon yokes 73 and are fully articulating in x, y, z axes, as depicted inFIG. 30. The e-beam fields emitted by the e-beam emitters may beconfigured in a horizontal fashion, vertical fashion or at some otherangle as desired. Additional structures regarding these sterilizationunits will be further described below in conjunction with the otherstructures of the second module 14. Operation of these e-beam emitterswill also be described in greater detail below. As will be appreciatedfrom the description below, the various e-beam emitters sterilizecertain components of the second module 14 during operation of thesystem 10 when containers are being filled and capped. Thus, the e-beamemitters provide active sterilization, or re-sterilization of componentsas the system 10 operates.

Isolator

Containers C sterilized by the first module 14 are first delivered tothe isolator assembly 52 of the second module 14. As shown in FIGS.10-14, the isolator assembly 52 generally includes an air lock structure76, a first intake wheel 78, a second intake wheel 80 and a housing 82having an air system 84 operably associated therewith.

As shown in FIG. 12-14, the air lock structure 76 is positioned at aninterface area 86 between the first module 12 and the second module 14and, in particular, at the inlet of the isolator assembly 52. The airlock structure 76 has a horizontal wall 88 and first depending wall 90and a second depending wall 92 and defining an open bottom end 94. Theair lock structure 76 provides a shroud structure. The walls 88, 90, 92are connected to a dividing wall of the first module 12 and, therefore,generally provides a seal around the opening between the first module 12and the second module 14. The first intake wheel 78 has a plurality ofgrippers 79 and is positioned such that as the wheel 78 rotates, thegrippers 79 are proximate the air lock structure 76. As will beexplained in greater detail below, the grippers 79 cooperate with awheel with grippers of the first module 12 to receive sterile containersC from the first module 12. The second intake wheel 80 has a pluralityof grippers 81 and is positioned proximate the first intake wheel 78 andcooperates therewith as described below. It is understood that the firstintake wheel 78 and second intake wheel 80 are powered and haveappropriate systems for rotation and operation of the respectivegrippers 79, 81. It is further understood that a single intake wheelcould be employed if appropriate sizing and number of grippers wascompatible with the size of the filler assembly 46 and transfer wheelassociated with the first module 12.

The housing 82 of the isolator assembly 52 has a floor 96, a pluralityof sidewall members 98 and top member 100 defining an enclosure 102 thatis positioned around the first intake wheel 78 and the second intakewheel 80. One sidewall member 98 has a container inlet opening 104 andis connected to the air lock structure 76 wherein the air lock structure76 is in communication with the enclosure 102. A second side wall 98 isprovided with a container outlet opening 106 positioned proximate thefiller assembly 46. The side wall members 98 may have a window 108 foroperators to see into the housing 82. The windows 108 each have hingesto allow for easy access to the first intake wheel 78 and the secondintake wheel 80. The windows 108 can further have window locks and sealsplaced around the perimeter of each window 108. The top member 100 hasan opening 110 that serves as an air inlet for connection to an air ductof an air management system to be described in greater detail below. Theair supply assists in maintaining a positive pressure and downward flowinto the housing 82 and out of the open bottom 94 of the air lockstructure 76. The floor can have a slanted portion 112 towards one ofthe sidewall members 98, which may be equipped with an access door 114.The access door 114 may be equipped with an air cylinder 115 operablyconnected between the sidewall 98 and the door 114 to provide automatedopening and closing of the door 114. The sidewall members 98 can beformed from individual layers of lead and plywood with a stainless steelcovering. The members 98 may be provided with a rubber seal, which mayabut around the air lock structure 76 and against the first module 12 toprovide additional sealing. The isolator assembly 52 can be providedwith a container reject mechanism associated with the second intakewheel 80. The container reject mechanism is adapted to reject containersunsuitable for filling, such as containers inadvertently deformed duringthe sterilization process in the first module 12. The container rejectmechanism 101 can be provided with a cam that is adapted to open thegrippers and a sensing mechanism that is adapted to sense deformedcontainers.

It is noted that depending on the characteristics of the type of thefiller assembly used and the type of first module used, alternativestructures to the isolator assembly 52 can be used to transfercontainers from the first module to the filler assembly. In thisexemplary embodiment a structure or intake conveyor is used to accept asterile container C from the first module 12 and deliver the container Cto the filler assembly 46. The isolator assembly 52 achieves this in theexemplary embodiment as the isolator assembly 52 is in an initialsterile condition and remains in such condition during operation of thesystem 10.

Filler Assembly 46

The filler assembly 46 includes components to receive the sterilecontainers C and further to receive a supply of batched, finishedproduct such as a liquid beverage to be injected or filled into thecontainers C. The filler assembly 46 generally includes a filler wheel47, the filler wheel sterilization unit 70, and a filler wheel airmanagement/isolation system 118.

The filler wheel 47 is a generally circular structure and has supportingsystems for rotation. As shown in FIGS. 15 and 15 a, the filler wheel 47has a plurality of filler valves 120 positioned generally adjacent oneanother and at a periphery of the filler wheel 47. The filler valves 120are operably in fluid communication with the supply of the batchedproduct through suitable conduits, lines, or hoses as is known. In theexemplary embodiment, the filler valves 120 are non-contact valves whichdo not contact the containers C; however, it is noted that contactvalves can be used. The filler wheel 47 further has a plurality offiller grippers 122 corresponding to the number of filler valves 120.The grippers 122 are positioned generally below the filler valves 120and grip the containers C received from the second intake wheel 80 ofthe isolator assembly 52. The filler wheel has a container inlet portion49 and a container outlet portion 51. The filler wheel 47 is generallypositioned proximate the second intake wheel 80. While the filler wheel47 is a rotary mechanism, other types of fillers can be used such aslinear fillers.

An exemplary filler valve 120 is depicted in FIGS. 41 and 42. As shownin FIG. 41, the filler valve structure generally has reduced sidewallsurfaces to reduce shadowing of e-beams during sterilization to permit amore effective active sterilization of the valve. FIG. 42 depicts apartial cross-sectional view of the filler valve 120. The filler valve120 is provided with a cap mechanism 121 for use in conjunction with aCIP procedure. FIG. 42 also shows the valve 120 having a cap on itsdistal end used in a clean in place procedure for cleaning the valvesprior to operation.

Filler Wheel Sterilization

The filler wheel sterilization unit 70 generally includes a first fillerwheel e-beam emitter 124 and a second filler wheel e-beam emitter 126.The e-beam emitters 124, 126 provide sterilization during operation ofthe filler wheel and provide an active sterilization zone. The fillerwheel e-beam emitters 124, 126 are positioned proximate the filler wheel47 between container inlet portion 49 and container outlet portion 51and within an opening associated with the filler wheel air managementsystem 118 to be described. The e-beam emitters 124,126 are mounted onyokes that are fully-articulating along multiple axes as indicated inFIG. 17. The e-beam emitters 124, 126 are positioned proximate a lowerportion of the filler assembly 46 and are directed upwards towards thefiller grippers 122, such that they are directed at an underside surfaceof the filler grippers 122 and filler valves 120. The e-beam emitters124, 126 emit an electron field and in one exemplary embodiment, therespective electron fields overlap one another as shown in FIG. 15 a. Aswill be described in greater detail below, as the filler wheel 47rotates, the filler valves 120 and the grippers 122 pass throughelectron fields to sterilize the valves 120 and grippers 122.

As can be appreciated from FIGS. 10 and 15-17, before the containers Care placed on the filler wheel 47, the filler wheel e-beam emitters 124,126 sterilize the filler grippers 122 prior to receiving the containersC. In addition, the filler wheel e-beam emitters 124, 126 are positionedsuch that they also sterilize the filler valves 120 just before thefiller valve heads provide product to the containers. Because of thedegree of impingement at which the filler wheel e-beam emitters 124, 126are positioned, the filler valves pass through the electron beam fieldsimultaneously with the grippers 122. This allows the electron beamfield to contact each of the filler valves 120, filler valve heads, andgrippers. Any microorganisms, therefore, that might be present on thefiller valve heads and the grippers are killed, and both will remainsterile. The electron beam zone produced by the filler wheel e-beamemitters 124, 126 fully encompass the heads of the filler valves 120 tosterilize all sides prior to filling. By sterilizing the filler valveheads just before each filling event, it is guaranteed that anymicroorganisms present on the filler valve head are not transferred tothe product. By way of example, in a filler wheel 47 having anapproximate seventy-six (76) inch diameter and supporting sixty (60)filler valves, each valve 120 and gripper 122 can be dosed once everysix (6) seconds by the filler wheel e-beam emitters 124, 126 in order toaccomplish sufficient sterilization. Once the containers C are filled,the containers C are passed off to the transfer mechanism 54 to bedescribed.

Filler Wheel Air System

In an exemplary embodiment, as shown in FIGS. 16-23, the filler wheel 47is provided with the localized filler wheel air management system 118.The filler wheel air management system 118 generally includes an inletmanifold 128, an intermediate supply section 130 and a generally annularchannel 132. As described in greater detail below, the air managementsystem 118 provides a conduit for a supply of air proximate an openingof the container C as the container C is being filled with product bythe filler wheel 47.

As shown in FIGS. 17-22, the inlet manifold 128 has a generally curvedconfiguration and may be considered to be horseshoe shaped. As such, theinlet manifold has a pair of ends 134 defining a gap 136 therebetween.The inlet manifold 128 has an opening at an intermediate section that isin communication with an inlet duct 138 that delivers a supply of HEPAfiltered air to be described in greater detail below. As further shownin FIGS. 17, 18 and 20-22, the inlet manifold 128 is tapered towards theends 134 and thus the manifold 128 has a greater volume at locationsbetween the ends 134. The tapered ends assist in keeping air velocitiesconstant in the inlet manifold 128. The inlet manifold has a top surface140 having a plurality of openings 142. The intermediate supply section130 has a vertical member 144 having one end connected to the opening142 and another curved end having a diverging outlet section 146defining an increased outlet area. It is appreciated that the divergingoutlet section 146 will direct a supply of filtered air in a generallyhorizontal direction.

The annular channel 132 is generally mounted around the filler wheel 47.It is understood that the annular channel 132 has a gap 133 generallydefining wherein the containers C enter and exit the annular channel132. The annular channel 132 has an inner annular wall 148 and an outerannular wall 150. The inner annular wall 148 is spaced from the outerannular wall 150 to define a pathway 152 therebetween. The annularchannel 132 further has an annular bottom wall 154. The inner annularwall 148 has an opening 156 wherein the inner annular wall is mounted onthe filler wheel 47 wherein the outlet section 146 is aligned with theopening 156 in the inner annular wall 148. As further shown in FIGS. 17and 23, the inner annular wall 148 has a screen 158 positioned over theopening 156. Any mesh screen or structure that provides a uniformpattern and distribution of air is suitable for covering the opening156. Moreover, the desired airflow may be accomplished without anystructure covering the opening all together. The outer annular wall 150may be in the form of a plurality of removable segments 160. Theremovable segments 160 may have windows such that operators can view thecontainers C in the pathway 152.

As further shown in FIG. 17, it is understood that the intermediatesupply section 130 comprises a plurality of supply sections 130.Accordingly, a plurality of vertical members 144 extends upwards fromrespective openings 142 in the inlet manifold 128. Each diverging outletsection 146 is positioned adjacent one another around the filler wheel47 wherein the outlets 146 collectively are in communication with theopening 156 in the inner annular wall 148. Smooth connections betweenadjacent outlet sections 146 assist in maintaining smooth air flow. Aswill be described in greater detail below, the components of the fillerwheel air management system 118 collectively define a conduit for thedelivery of filtered air proximate an opening of the containers C as thecontainers C are being filled by the filler valves 120.

Transfer Mechanism

As shown in FIGS. 25 and 26, the transfer mechanism 54 transferscontainers C filled with product from the filler assembly 46 to thecapper assembly 48. The transfer mechanism 54 generally includes atransfer wheel 162, the transfer mechanism e-beam sterilization unit 72and a transfer mechanism air management/isolation system 164.

The transfer wheel 162 is a generally circular structure and hassupporting systems for rotation. The transfer wheel 162 has a pluralityof grippers 163, a container inlet portion 181 and a container outletportion 183. The transfer wheel 162 is generally positioned adjacent tothe filler assembly 46 such that it can receive filled containers C fromthe filler assembly 46. However, any suitable transfer mechanism can beused for transferring the filled containers from the filler assembly 46to the capper assembly 48. For example, a mechanism could be used thattransfers containers C from the filler assembly 46 in a linear fashionif desired.

Transfer Wheel Sterilization Unit

In an exemplary embodiment, the transfer mechanism e-beam sterilizationunit 72 generally includes a single transfer e-beam emitter 166positioned adjacent to the transfer wheel 162 between the containerinlet portion 181 and the container outlet portion 183 and directedtowards the wheel 162. It is understood that additional e-beam emitterscould also be utilized with the unit 72. After the containers C havebeen filled with beverage product, the containers C are transferred tothe capper assembly to be sealed with a closure. It is necessary tosterilize the grippers 163 holding a filled, open container C, and thetravel zone just above the containers, so that contamination is notintroduced onto the container mouth or into the product. Thus, as shownin FIGS. 10 and 11, before receiving the container C from the fillerwheel 47, the e-beam field produced by the transfer wheel e-beam emitter166 sterilizes the grippers 163 located on the transfer wheel 162. Inone embodiment, the transfer wheel 162 has a diameter of approximatelyforty (40) inches. At 600 bpm, therefore, each gripper 163 is dosed bythe transfer wheel e-beam emitter 166 approximately once every 2.8seconds. After sterilization, the grippers 163 on the transfer wheel 162receive the containers C from the filler assembly 46, and transfer thecontainers C to the capper assembly 48 to place a cap 202 on each filledcontainer C.

Transfer Mechanism Air Management System

In an exemplary embodiment shown in FIGS. 25 and 26, the transfer wheel56 is provided with the local air management system 164. The transfermechanism air management system generally includes an inlet duct 168 andan outlet manifold 170.

The inlet duct 168 generally includes an air line having one endconnected to a supply of ULPA/HEPA filtered air. The duct 168 has adiverging outlet end 172 having an increased outlet area. In anexemplary embodiment, the inlet duct 168 comprises a plurality of spacedducts 168, each having a diverging outlet end 172. The inlet ducts 168may all be connected to the common filtered air source.

The outlet manifold 170 generally has a top wall 174 and a pair ofdepending walls 176. The outlet manifold 170 generally has a U-shapedcross section. The top wall 174 has an opening 178 that correspond andare in communication with the diverging outlet ends 172 of the inletducts 168. As shown in FIG. 26, a screen 180 is positioned against anunderside surface of the top wall 174 and over the openings 178. Againany mesh screen or structure that provides a uniform pattern anddistribution of air is suitable for covering the openings 178. Also asstated above with respect to the filler assembly, the desired airflowmay be accomplished without any structure covering the openings alltogether. The outlet manifold 170 has a curved configuration and has alength that covers a portion of the transfer wheel 162. In one exemplaryembodiment, the outlet manifold 170 has an inlet end 173 positionedproximate the filler assembly 46 and an outlet end 175 positionedproximate the capper assembly 48. As will be described in greater detailbelow, the components of the transfer mechanism air management system164 provides a conduit that delivers filtered air in a downwarddirection towards the top of the open containers C.

Capper Assembly

As shown in FIG. 29, the capper assembly 48 places a cap on a respectivefilled container C received from the transfer mechanism 54. This is donewhile maintaining a sterile environment. As shown in FIGS. 28, 29, and35, the capper assembly 48 generally includes a capper wheel 190, thecapper wheel sterilization unit 74, and a cap loader 192.

The capper wheel 190 is a generally circular structure and hassupporting systems for rotation. The capper wheel 190 has a plurality ofgrippers 191 as well as a plurality of cap chucks 193 designed toreceive a cap to be described. The grippers 191 receive the filledcontainers from the transfer wheel 162. The cap chucks 193 haveassociated structure to hold caps therein as well as for rotationalmovement. The capper wheel 190 is generally positioned adjacent to thetransfer mechanism 54 and discharges filled and capped containers C forfurther packaging.

The capper wheel sterilization unit 74 includes a plurality of e-beamemitters, namely: a first cap e-beam emitter 194, a second cap e-beamemitter 196, a third cap e-beam emitter 198 and a fourth cap e-beamemitter 200. The first cap e-beam emitter 194 and the second cap e-beamemitter are positioned generally adjacent one another at a locationadjacent the capper wheel 190 where caps are initially installed onto arespective cap chuck 193. The electron fields produced by the emitters194, 196 may overlap and in conjunction with the rotation of the capchuck 193, it is assured that all surfaces of the cap will besufficiently sterilized. The third cap e-beam emitter 198 and the fourthcap e-beam emitter are positioned adjacent a further rotational path ofthe capper wheel 190 to provide a sterile field that is occupied by thefilled container C while a cap is screwed onto the container C, to bedescribed further.

Cap Loader

The cap loader 192 has a slotted plate have structure for rotation ofthe plate. The slot is dimensioned to receive a cap. A cap chute can beprovided to deliver caps to each slot in the plate. As is known, the capchuck 193 is moved by the capper wheel 190 in operable cooperation withthe cap loader 192 wherein a cap is loaded in the cap chuck 193.

Environment Control System

As shown in FIG. 36, the system 10 further includes an overallenvironment control system 220. The system 220 assists with the airmanagement systems discussed above as well as providing additionalsystems and structures to aid in filling and capping the containers C inan active sterilization zone in the CHE 18. The environment controlsystem generally includes a housing enclosure 222, a filtered airdelivery system 224 and an H2O2/Ozone treatment system 226.

The housing enclosure 222 generally encloses the components of thesecond module 14. As shown in FIGS. 10, 11, 11 a, and 36, the housingenclosure 222 has a plurality of walls and barriers 228 positionedaround the components of the second module 14. Access doors 230 may beprovided for operators or other personnel to gain access to the secondmodule 14. The walls and barriers include x-ray and irradiationshielding such as stainless steel wrapped lead panels reinforced withplywood to prevent operator exposure to the electron beams. In addition,windows (not shown) composed of leaded glass allow the operators tovisually inspect operation of the second module. In one exemplaryembodiment, the housing enclosure 222 may also be considered a part ofthe CHE. This structure may be formed such that it may be considered atClass 1000-10,000 enclosure.

The filtered air delivery system 224 comprises a plurality of filteredair sources that direct air to various parts of the system. As furthershown in FIG. 36, a first set 232 of filtered air delivery systems 224is provided to deliver filtered air to the container sterilizer 32. Eachsystem 232 has a blower 234 and ULPA/HEPA filter 236. One of the systemsin this set may also include a heated steam source 238. These systemsprovide ULPA or HEPA filtered air to the container sterilizer 32 therebymaintaining a positive pressure in the sterilizer 32. This air can bevented from the sterilizer 32. A second set 240 of filtered air deliverysystems is provided to deliver filtered air to certain components of thesecond module 14. An isolation sterile air supply system 242 is providedand has a pre-filter 244, a blower 246, a heated steam source 248 and aULPA/HEPA filter 250. The isolation sterile air supply system 242 has afirst output 252, a second output 254 and a third output 256. The firstoutput 252 is connected to the top member opening 110 (FIGS. 11 and 11a) of the isolator 52. The second output 254 is connected to the fillerwheel air management system 118. The third output 256 is delivered tothe transfer wheel air management system 164. An enclosure air supplysystem 258 has a blower 260 and a ULPA/HEPA filter 262 to providefiltered air and positive pressure to the housing enclosure 222.

Finally, as further shown in FIG. 36, the H2O2 treatment system 226 hasassociated blowers 264 and an H2O2 module 266. However, any suitableform of chemical treatment can be used that can remove ozone from thesecond module. The treatment system 226 is operably connected to boththe container sterilizer 32 and the housing enclosure 222. The secondmodule 14 is vented to remove any ozone caused by the emitters, and theair is treated prior to release into the atmosphere.

Overall Operation of the System 10

Overall operation of the system 10 will now be described. It isunderstood by those skilled in the art that the system 10 has thenecessary power sources and associated controllers to effect and controloperation of the system 10 as known by those skilled in the art. Thecomponents of the first module 12 and the second module 14 are initiallyset-up wherein the system 10 is ready to receive containers for fillingand capping. Moreover, before operation, the system 10 is pre-sterilizedusing chemicals such as hydrogen peroxide and further in conjunctionwith the e-beam emitters. Other pre-sterilization techniques could alsobe used. Thus, prior to operation of the system 10, the system 10 issterilized to eliminate any contaminants or microbes etc. As will bedescribed below, the structures of the system 10 provide various activesterilization zones and confined hygienic environments during operationof the system 10 as containers C proceed through a path of travelthrough the system 10.

Operation of the First Module

As can be appreciated from FIGS. 4 and 5, empty containers C, typicallyin the form of plastic beverage containers are removed from pallets andloaded onto the conveyor 20 by the de-palletizer 22. The conveyor 20delivers the containers C to the waterless rinser 30 wherein clean,compressed air is delivered to the containers C wherein the containers Care thoroughly rinsed and any contaminants are vacuumed away. Theconveyor 20 delivers the containers C to the container sterilizer 32.The container sterilizer 32 may also include ULPA/HEPA filtered airtreatment as well as H2O2 treatment on the container C. The high-energye-beam emitters of the container sterilizer 32 produce an electron fieldthat encompasses the pathway taken by the containers C. As discussed,the container sterilizer 32 may have suitable structure to invert thecontainers C to assure that all surfaces of the containers 32 aresterilized. As such, once the containers C reach the outlet wheel of thecontainer sterilizer 32, the containers C are in a clean, sterile state.As previously discussed, the container sterilizer 32 utilizeshigh-energy e-beam emitters in one exemplary embodiment. Other forms ofcontainer sterilization could also be used in the first module 12 asdesired. The ultimate result of the first module 12 is the delivery ofsterile containers C to the second module 12 as shown in FIG. 32.

Operation of the Second Module

As discussed above, before operation of the second module 14, the secondmodule 14 is sterilized using a chemicals and e-beam treatment. Certaincomponents of the system may include built-in systems for such cleaningsuch as the inlet manifold of the filler wheel air management system.Structures may also be provided to inject cleaning liquids such as waterand/or hydrogen peroxide through screens in the air management systems.

As further shown in FIG. 37, the containers C are delivered from thefirst module 12 to the second module 14 at the interface area 86generally defined by the air lock structure 76 of the isolator assembly52. Any access windows and doors of the isolator assembly 52 are closed.As is appreciated from FIGS. 11, 11 a, and 36, ULPA/HEPA filtered air isdelivered to the isolator assembly by the isolation sterile air supplysystem 242 to maintain a positive air pressure in the isolator assembly52. As the air lock structure 76 has the open bottom end 94, thesupplied air may pass downwards through the open bottom end 94. Thesupplied air may then pass into the housing enclosure 222 and can bevented as desired as it is understood that the housing enclosure 222 isvented. In sum, positive air pressure is maintained as well as downwardair flow to assist in assuring any potential microbes are directed awayfrom the containers C, including the openings of the containers C. Thecontainers C are passed from the outlet wheel of the first module 12 andto the first intake wheel 78 via the grippers 79. The first intake wheel78 passes the containers C to the second intake wheel 80 via thegrippers 81. It is understood that the grippers 79, 81 as well as theenvironment of the isolator assembly 52 are all in sterile conditions.The second intake wheel 80 then delivers the sterile containers C to thefiller assembly 46 through the container outlet opening 106. TheULPA/HEPA air is constantly circulated by the intake wheels 78, 80 andgrippers 79, 81 and maintaining sterile conditions. The isolatorassembly 52 may be considered passive sterilization is the assembly 52is initially sterilized and then wherein the air flow assists inmaintaining the sterile conditions.

As previously discussed, the container reject mechanism 101 senses thecontainers C proximate the second intake wheel 80 and determines whetherany container C has been damaged during the sterilization process in thefirst module 12. This can happen, for example, such as if thesterilization process in the sterilizer 32 deformed a wall of thecontainer C making the container C unsuitable for filling and capping.In such case, the container reject mechanism senses the deformedcontainer C and ejects the container C from the grippers 81 and therejected container C falls to the floor 96 of the isolator assembly 52.In this fashion, the grippers 81 receive a signal to open wherein thegrippers 81 drop the container C. The slanted portion 112 of the floor96 directs the container C to the access door 114. The air cylinder 116can be actuated to open the access door 114 wherein the rejectedcontainers C can be removed from the isolator assembly 52 and discarded(FIG. 12). It is understood that the system 10 is designed such that ifa container C is rejected and leads to a filler valve/gripper on thefiller wheel 47 not being loaded with a container C, the filler valvewill not be actuated to deliver liquid product etc. As previouslydiscussed, depending on the sizing of the outlet wheel of the firstmodule 12 and the intake wheel of the second module 14, only a singleintake wheel in the isolator assembly 52 could be employed.

As further shown in FIG. 38, the filler wheel 47 receives the containersC from the second intake wheel 80 at the container inlet portion 49. Assuch, the grippers 122 on the filler wheel 47 grip the containers C fromthe grippers 81 on the second intake wheel 80. The containers C are thuspositioned below an associated filler valve 120, and the containers C,grippers 81, and filler valves 120 travel in an arcuate path as thefiller wheel 47 rotates. Just prior to the transfer from the secondintake wheel 80 to the filler wheel 47, the grippers 122 on the fillerwheel 47 are sterilized. To this end, the first filler e-beam emitter124 and the second filler e-beam emitter 126 provide electron fieldsthat overlap one another. (See e.g., FIG. 15 a). The electron field islarge enough such that the field encompasses the path travelled by thegrippers 122 and filler valves 120 of the filler wheel 47. As shown inFIG. 38, it is understood that the e-beam emitters 124, 126 arepositioned such that the grippers 122 are sterilized just prior toreceiving the sterile containers C from the second intake wheel 80.Moreover, to accomplish this, the e-beam emitters 124, 126 arepositioned between the container inlet portion 49 and the containeroutlet portion 51. The grippers 122 and valves 120 are sterilized asthese components will contact the containers C. Thus, sterile conditionscontinue to be maintained as the grippers 122 and valves 120 areactively re-sterilized upon constant rotation of the filler wheel 47.

Next, the beverage product is injected into the containers by the fillerassembly 46. Because of the unique sterilization structures andprocesses used herein, the product can be delivered generally at ambienttemperature and aseptic conditions. Elevated product temperatures arenot required. Product is injected into the containers C as the fillerwheel 47 rotates around its central axis. In particular, the fillervalves 120, which are in fluid communication with the batched liquidproduct, are activated to begin to fill the containers C. The fillervalves 120 fill the containers C as they rotate on the filler wheel 47.As previously discussed, the filler wheel air management system 118supplies ULPA/HEPA filtered air to the filler wheel 47 during thefilling process. The second output 254 (FIG. 36) of the isolation airsupply system 242 provides filtered air to the inlet manifold 128 of thefiller wheel air management system 118. Thus, the entire curved manifold128 is filled. The tapered design of the manifold 128 assures a steadysupply of filtered air and keeping air velocities constant. As can beappreciated from FIG. 23, the filtered air continues upwards through theintermediate supply section 130 and through the diverging outletsections 146. The diverging outlet sections 146 assist in creating anair flow to the containers C. The air continues through screen 158 andthus, filtered air is provided into the annular channel 132. As furthershown in FIG. 23, the outlet sections 146 and screens 158 are generallypositioned proximate the openings of the containers C. The screen 158provides a certain amount of resistance to the air flow to provide anice steady air flow into the entire annular channel 132. Because of thestructure of the annular channel 132 via the inner annular wall 148 andthe outer annular wall 150 air flow is generally directed around thecontainer opening and downwards along the longitudinal axis of thecontainers C and downwards in the annular channel 132. It is understoodthat certain gaps remain in the bottom portions of the annular channel132 wherein the filtered air can escape downwards into the environmentof the housing structure 222. Thus, the annular channel 132 ispressurized by the supply of filtered air. FIG. 24 generally shows theair flow about the container C as product is injected into thecontainer. This airflow helps to isolate the container C and furtherminimize any chance of microbes or other unwanted materials fromentering the container C. Air flow is directed generally proximate theneck portion of containers C. As depicted in FIG. 24, air flows at theneck portion, around the outer circumference of the neck portion of thecontainer, and downwards following the path of the outer circumferenceof the container parallel to the container axis. Thus, positive airpressure is maintained around this portion of the container C anddirected downwards away from the openings of the containers C. However,the particular airflow patterns are not critical so as long as apositive air pressure is maintained in the annular channel 132.

Accordingly, the filler grippers 122 are sterilized just prior toengaging a container C in sterile fashion and filtered air is providedabout the container C to enhance and maintain sterile conditions as thecontainer C is being filled. Once the container C rotates about thefiller wheel 47, the filling process is designed to be complete. Thecontainer C can then be passed to the transfer mechanism 54 at thecontainer outlet portion 51.

As shown in FIG. 39, the transfer mechanism 54 receives the containers Cfrom the filler wheel 47 at the container inlet portion 181 andtransfers the containers C to the capper assembly 48 at the containeroutlet portion 183. Prior to receiving the filled, open containers Cfrom the filler wheel 47, the grippers 163 of the transfer wheel 162 aresterilized by the transfer wheel e-beam emitter 166 positioned betweenthe container inlet portion 181 and the container outlet portion 183. Asshown in FIGS. 11, 11 a, and 39, the transfer wheel e-beam emitter 166is positioned adjacent the transfer wheel 162 and provides a sterileelectron beam field that encompasses the path that the grippers 163occupy as the transfer wheel 162 rotates about its central axis.Accordingly, just prior to the grippers 163 gripping a filled, opencontainer C from the filler wheel 47, the grippers 163 are sterilized bythe transfer wheel e-beam emitter 166. Thus, the sterile condition ofthe container C continues to be maintained.

As previously discussed, the transfer mechanism air management system164 provides ULPA/HEPA filtered air to the containers C at the transferwheel 162. The third output 256 (FIG. 36) of the isolation sterile airsupply system 242 provides sterile air to the inlet duct 168 anddiverging outlet ends 172. The filtered air is directed downward throughthe screen 180 and into the outlet manifold 170. The screen 180 providesa certain amount of resistance to assure flow downwards over the open,filled containers C as they traverse on the transfer wheel 172. It isunderstood that the air management system 164 has a length generallycorresponding to when the transfer wheel grippers 163 engage a containerC to the time the grippers 163 pass the containers C to the capperassembly 48. The filtered airflow is directed at the container openingsin a downward fashion to form an air curtain and assists in keepingmicrobes or other contaminants away from the openings of the containersC. FIGS. 26 and 27 show the filtered airflow about the openings of thecontainers wherein the airflow is directed downwards past the containersC. The filtered airflow is vented to the housing enclosure 222.

As shown in FIG. 40, the filled containers C are transferred from thetransfer wheel 162 to the capper wheel 190 of the capper assembly 48. Anadditional separator plate may be provided with the transfer wheel 162to make sure that any e-beam field associated with the capper assembly48 is not directed into an open filled container C. Capper wheelgrippers 191 engage the filled, open containers C. Prior to thisengagement, the capper wheel 190 is prepared for capping the containersC with a cap 202. As discussed, the capper wheel 190 has a plurality ofcapper chucks 193 that will receive a cap 202 to be placed onto acontainer C. Prior to this operation, however, the caps, 202, capperchucks 193 and capper grippers 191 are sterilized to maintain thesterile conditions of the overall process.

As shown in FIGS. 28, 29, 35, and 40, a first capper wheel e-beamemitter 194 is positioned to focus its electron field to encompass thepath travelled by the capper chucks 193. In this fashion, the capperchucks 193 are sterilized prior to receiving a cap 202 at a startposition 201. As the capper chucks 193 continue to rotate on the capperwheel 190, the cap loader 192 functions to insert a cap 202 into thecapper chuck 193. The cap loader 192 includes a rotating plate havingslots to receive caps 202 may be fed to the plate via a cap chute. Thecap loader 192 is positioned at an offset location to accommodate thecapper wheel e-beam emitters. As further shown in FIG. 29, the cap 202may extend a short distance beyond the cap chuck 193. Once a cap 202 isloaded onto the cap chuck 193, the second capper wheel e-beam emitter196 is focused upwardly towards an underside of the cap 202, as shown inFIGS. 31-34. The electron field generated by the second capper wheele-beam emitter 196 encompasses the path traveled by the capper chuck 193carrying the cap 202. In this fashion, the underside surface of the cap202 is sterilized by the second capper wheel e-beam emitter 196 at a caploaded position 203. As the capper chuck 193 continues to be rotated bythe capper wheel 190 along an arcuate path, the capper chuck 193 rotatesitself approximately 180 degrees while in the electron beam fieldgenerated by the second capper wheel e-beam emitter 196. It isunderstood that the cap 202 has a depending skirt wherein a portion ofthe underside surface could be obstructed from penetration by theelectron field because of the depending skirt of the cap 202. With thecapper chuck rotation 193, this potentially obstructed surface is thenrotated 180 degrees where it can confront the second cap e-beam emitter196. While the cap 202 can be sufficiently sterilized without rotationof the capper chuck 193, the rotating capper chuck 193 within the fieldof the second capper wheel e-beam emitter 196 further enhances thesterility of the cap 202.

The capper wheel 190 continues to rotate the caps 202 held by arespective capper chuck 193 wherein the transfer wheel 162 passes theopen, filled container C to the capper grippers 191 on the capper wheel190. The capper chuck 193 then rotates the cap 202 onto the filledcontainer C held by the capper grippers 193 moving in a downwarddirection a indicated by the arrow in FIG. 29. As further shown in FIGS.29, 35 and 40, during this process, the third capper wheel e-beamemitter 198 and the further capper wheel e-beam emitter 200 generateelectron beam sterile fields that encompass the path of the capper wheel190 and, in particular, the path of the capper chuck 193 with cap 202 asthe cap 202 is screwed onto the container C held by the capper gripper193. As depicted by the arrow in FIG. 29, the capper moves downward toinstall the cap onto container C. The third and fourth e-beam emitters198, 200 focus their respective fields on the airspace between thecontainer C and cap 202 as the cap 202 is screwed onto the container C(e.g., below the capper chuck and proximate the capper grippers), thusmaintaining the sterility of the capping process at a cap installationposition 205. The angle of the third and fourth e-beam emitters 198, 200allows the airspace and the capper chuck 193 to be sterilizedsimultaneously. Additionally, after the capper chuck 193 screws the cap202 onto the container C, the third and the forth e-beam emitters 198,200 sterilize the outside surface of the cap 202 as the capper chuck 193is raised off of the cap 202 at a finished position 207.

Once capped, the containers C are further advanced by the capper wheel190 and then directed to further portions of the conveyor 20 where thecontainers C are transported out of the second module 14 for furtherpackaging operations 24 (FIGS. 4 and 35) and later shipment.

Thus, as can be appreciated from the above description, the containers Care filled, transferred, and capped in confined hygienic environmentsand active sterilization zones are provided in the second module 14during operation. These systems prevent surface contamination andairborne contamination. The overall pathway of the container C iscontrolled in the filling and capping of the containers C. Thecomponents of the system 10 and, in particular, the components of thesecond module 14, provide a hostile environment for any potentialcontaminants or microbes. Because the system is treated chemically andwith e-beams prior to operation, it initially starts out in a sterilecondition. The various e-beam emitters, placed at strategic locationsprovide active sterilization zones ensuring that sterile conditions aremaintained and that the containers C are not contaminated while beinghandled during the filling, transferring and capping operations. Theisolation systems, providing controlled sterile air flow during thehandling and filling operations, assist in maintaining the sterileconditions by providing CHE(s) that the containers C pass through whilebeing filled and capped. It is understood that the ULPA/HEPA air isconstantly supplied and changed out in the CHE during operation of thesystem 10. Each of the isolator air management system, the filler wheelair management system, and the local air management system of thetransfer wheel can alone or in combination be considered a CHE. TheCHE(s) in conjunction with the active sterilization zones all controlthe environment surrounding the pathway traveled by the container Cduring the filling, transferring, and capping operations. Accordingly,in one exemplary embodiment, the container C travels in a confinedhygienic environment during its movement in the second module 14 fromthe isolator assembly 52 to the capper assembly 48. With the design ofthe present system 10, it is appreciated that only critical surfaces aresubjected to e-beam sterilization while the product being filled in thecontainers C is not subjected to any e-beam sterilization orirradiation. With the design of the present system 10, it is understoodthat various types of beverages can be filled in containers C includinglow acid and high acid products. In addition, the product being filledin the containers C may be pre-treated as desired such that it hasreduced or inhibited microbial growth characteristics.

Alternative Second Module—E-Beam Assembly

In an alternative embodiment, the second module, and the e-beamsterilization unit in particular, can be modified as discussed below.Generally, additional e-beam emitters are utilized and the isolatorassembly 52 described above is not utilized. As depicted in FIGS. 43-49,the e-beam sterilization unit can generally include a first intake wheele-beam emitter F1, a filler wheel e-beam emitter F2, a transfer wheele-beam emitter F3, a first capper wheel e-beam emitter F4, a secondcapper wheel e-beam emitter F5, a first cap chute e-beam emitter C1, anda second cap chute e-beam emitter C2.

Again, the e-beam emitters are positioned such that only criticalmachine surfaces, components, and air immediately surrounding thecomponents are subjected to the e-beams and not the beverage productitself. In one exemplary embodiment, the e-beam assembly is arrangedaccording to the description below. The first transfer wheel e-beamemitter F1 has an e-beam zone located at approximately 9 o'clock on thefirst transfer wheel 554. The filler wheel e-beam emitter F2 has ane-beam zone located at approximately 5 o'clock on the filler wheel 547.The second transfer wheel e-beam emitter F3 has an e-beam zone locatedapproximately at 12 o'clock on the second transfer wheel 556. The firstcapper wheel e-beam emitter F4 has an e-beam zone located approximatelyat 6 o'clock on the capper wheel 557. The second capper wheel e-beamemitter F5 has an e-beam zone located approximately at 2 o'clock on thecapper wheel 557, which is proximate to the torque head and air spacebetween the cap and container finish. Again, it is understood thatvariations of the locations and numbers of the e-beam zones arepossible.

Alternative First Transfer Wheel Sterilization

In this alternative embodiment, as shown in FIG. 43, the isolator isremoved from the second module, and the first transfer wheel can beprovided with an e-beam emitter F1 to maintain the sterility of thecontainers. After the sterile containers travel through the airlockstructure (as discussed above), the containers are brought into thesecond module by the intake wheel 553 and transferred to the firsttransfer wheel 554. Since the first transfer wheel 554 grips thecontainer by its neck, grippers 570 on the first transfer wheel 554 aresterilized prior to receiving the containers C to prevent any microbesthat are present on the grippers 570 from contaminating the neck or themouth of the container, as depicted in FIG. 43. Thus, the grippers 570located on the first transfer wheel 554 are exposed to the e-beam zoneproduced by the first transfer wheel e-beam emitter F1. As shown in FIG.43, the first transfer wheel e-beam emitter F1 provides an electronfield that generally encompasses the grippers 570 rotating on the firsttransfer wheel 554. It is understood that the grippers 570 generallypass into and through the electron field. In one embodiment, the firsttransfer wheel 554 moves at a rate of approximately 21 rpm (600 bpm) andeach neck handling gripper 570 is dosed once every 2.8 seconds to ensurethat every container is gripped by a sterilized gripper. After thegrippers 570 are exposed to the e-beam zone produced by the firsttransfer wheel e-beam emitter F1, the grippers 570 receive thecontainers from the intake wheel 553 of the conveyor 520 that may beconsidered associated with the first module. The first transfer wheel554 then delivers the containers to the filler 546.

Alternative Filler Wheel Sterilization

As depicted in FIGS. 44 and 45, before the containers are placed on thefiller wheel 547, the filler wheel e-beam emitter F2 sterilizes thefiller wheel grippers 572 prior to receiving the containers. Inaddition, the filler wheel e-beam emitter F2 is positioned such that italso sterilizes the filler valves just before the filler valve headscontact the containers. Because of the degree of impingement at whichthe filler wheel e-beam emitter F2 is positioned, the filler valves passthrough the electron beam field simultaneously with the grippers 572.Any microorganisms, therefore, that might be present on the filler valveheads are killed, and the grippers 572 and the filler valve heads remainsterile. The electron beam zone produced by the filler wheel e-beamemitter F2 fully encompasses the filler valve heads to sterilize allsides prior to filling. By sterilizing the filler valve heads justbefore each filling event, it is guaranteed that any microorganismspresent on the filler valve head are not transferred to the product. Byway of example, in a filler with sixty (60) filler valve heads withapproximately a seventy-six (76) inch diameter filler wheel, each valveand gripper can be dosed once every 6 seconds by the filler wheel e-beamemitter F2 in order to accomplish sufficient sterilization. Once thecontainers are filled, the containers are passed off to the secondtransfer wheel 556.

Alternative Transfer Wheel Sterilization

After the containers have been filled with beverage product they aretransferred to the capper via the second transfer wheel 556 to be sealedwith a closure. It is necessary to sterilize the grippers 574 holding afilled, open container, and the travel zone just above the containers,so that contamination is not introduced onto the container mouth or intothe product. Thus, as shown in FIG. 39, before receiving the containerfrom the filler wheel 547, the e-beam zone produced by the secondtransfer wheel e-beam emitter F3 sterilizes the grippers 574 located onthe second transfer wheel 556. In one embodiment, the second transferwheel 556 has a diameter of approximately forty (40) inches. At 600 bpm,therefore, each gripper 574 is dosed by the second transfer wheel e-beamemitter F3 approximately once every 2.8 seconds. After sterilization,the grippers 574 on the second transfer wheel 556 receive the containersfrom the filler 546, and transfer the containers to the capper wheel557, such that the capper 548 can cap each filled container.

Alternative Air System

In an alternative embodiment, the first and second transfer wheels andthe filler wheel can each be provided with a separate air system. Asdepicted in FIG. 51, the filler wheel 547 has a channel 506 thatsupplies ULPA filtered air from behind the filler valves. This createsan even distribution of air 540, moving away from the container finishand preventing contaminants from landing on the container finish, fillervalves, or neck grippers. Air 540 is evenly distributed through supplyducts stemming from the center of the filler wheel in a spoke-likepattern, as depicted in FIG. 50. As shown in FIG. 52, the second channel508 serves the same purpose on the transfer wheels 554, 556, 558. Thesecond channel 508 and channel cover 544 create a steady stream of airover the top of the container, pushing air out from the center of thetransfer wheels 554, 556, 558. The second channel 508 is formed suchthat an air curtain is created on the underside of the channel cover544. Velocities and volumes of air are such that the currents aregreater than the turbulent motion of the rotating filler and transferwheels. Airflow is created in a radial, outward direction away from theproduct and the critical container path. A similar method can be used onthe capper wheel 557.

FIG. 51 depicts an alternative exemplary method which can be implementedto provide air to the filler wheel. As depicted in FIG. 51, the fillerwheel 547 has a first channel 506 that supplies ULPA/HEPA filtered airfrom behind the filler valves 522. The filler wheel 547 has a channel506 that supplies ULPA/HEPA filtered air from behind the filler valves.This creates an even distribution of air 540, moving away from thecontainer finish and prevents contaminants from landing on the containerfinish, filler valves, or neck grippers. Air 540 is evenly distributedthrough supply ducts stemming from the center of the filler wheel in aspoke-like pattern, as depicted in FIG. 50.

In another exemplary embodiment, as depicted in FIG. 52, the thirdtransfer wheel 556 can include a second channel 508, which suppliesULPA/HEPA filtered air. The second channel 508 serves the same purposeon the transfer wheel 556. The second channel 508 and channel cover 544create a steady stream of air over the top of the container, pushing airout from the center of the transfer wheel 556. The second channel 508 isformed such that an air curtain is created on the underside of thechannel cover 544. Velocities and volumes of air are such that thecurrents are greater than the turbulent motion of the rotating fillerand transfer wheels. Airflow is created in a radial, outward directionaway from the product and the critical container path. A similar methodis to also be used on the capper wheel 557 if desired.

To further reduce contamination, the filling area of the filler wheel547 can be cleaned in a clean-in-place (“CIP”) procedure. As depicted inFIG. 53, the filler wheel 547 also houses a plate 620, which segregatesthe filler valves 522 and other moving parts from the container fillingarea 624. The filler valves 522 each have an associated filler port 632.Each filler valve 522 has an associated CIP capping mechanism 628. TheCIP capping mechanisms 628 are fixed in each one of ports 634. Each CIPcapping mechanism 628 has a CIP cap 626 and a capping arm 630, which isrotatably fixed on a capping post 636. As shown in FIG. 53, the plate620 is used in the aseptic design to segregate the filler valves 522 andmoving parts from the container filling area 624. This divisionmaintains a clean environment for the filling operation, and reduces theparts susceptible to contamination. Enclosing the filler valves 522 alsoreduces the turbulence caused by rotation of the filler wheel 547, andcontributes to greater airflow. The enclosed parts can be accessed formaintenance through a removable cover (not shown). This cold-filltechnique is part of the unique active sterilization zone developedunder this method.

Active Sterilization Zone Environment

The system of the exemplary embodiment is designed to eliminate microbesthat are physically transferred from component to component throughoutthe filling process and that culture or cultivate on the components ofthe system. The system utilizes e-beam technology to sterilize thecontainers, caps, and critical contact surfaces.

The emitters create an “active” sterilization zone such that thecontainers C remain in a sterilized environment until they exit to finalpackaging. The e-beams in combination with the air system aid in killingthe microbes on the critical contact surfaces of the system. In additionthe e-beam generators produce secondary e-beams and X-rays. The e-beamsalso react with oxygen (O2) and nitrogen to yield nitric acid and ozone(O₃). Each of the above (e-beams, air, x-rays, nitric acid, ozone (O₃),and secondary e-beams) aid in eliminating microbes in the system bystarving the microbes of necessities such as air, water, and othernutrients.

Traditional cold-fill lines, with their passive sterilizationtechniques, require that all components brought into the environment bepre-sterilized. They rely on this pre-sterilization to prevent anycontamination of the aseptic environment. Once the environment has beencontaminated, however, making the environment truly aseptic again isvery difficult. By having an active sterilization zone, any contaminantsthat may enter the zone can be immediately sterilized upon contact withcritical surfaces, minimizing system downtime and cost.

As can be appreciated with the exemplary embodiments disclosed herein,it is no longer necessary to heat the beverage product and to invert thehot container to sterilize the headspace. Since the containers are nothot, a container cooler is no longer necessary. The removal of these twopieces of equipment further simplifies and streamlines the containerfilling process. With the system of the exemplary embodiments,containers that were previously filled in a hot-fill process can now befilled at ambient temperatures wherein the product injected into thecontainers is at ambient temperatures. As such, containers are notrequired to have as robust a sidewall construction as before.Accordingly, the containers can be made with less material, resulting insignificant material cost savings. This also provides more flexibilityin container design. In addition, less energy is required as thebeverage product no longer needs to be held at the high temperature foras long. Also, the system allows for the sterile filling of containerswith the beverage, while not requiring additional preservatives to meetacceptable shelf-life requirements. In addition to the containermaterial savings, other sustainability benefits include water savings,natural gas savings and a reduction of greenhouse gases. The systemdesign further provides that the local filling point of the containersis re-sterilized at each and every filling event. Finally, the e-beamtechnology provides acceptable dosing in a fraction of a second, therebyproviding for an enhanced in-line sterilization and filling process.

Several alternative embodiments and examples have been described andillustrated herein. A person of ordinary skill in the art wouldappreciate the features of the individual embodiments, and the possiblecombinations and variations of the components. A person of ordinaryskill in the art would further appreciate that any of the embodimentscould be provided in any combination with the other embodimentsdisclosed herein. It is understood that the invention may be embodied inother specific forms without departing from the spirit or centralcharacteristics thereof. The present examples and embodiments,therefore, are to be considered in all respects as illustrative and notrestrictive, and the invention is not to be limited to the details givenherein. Accordingly, while the specific embodiments have beenillustrated and described, numerous modifications come to mind withoutsignificantly departing from the spirit of the invention and the scopeof protection is only limited by the scope of the accompanying claims.

1. An apparatus comprising: a transfer wheel configured to transfer openfilled containers from a filler assembly to a capping assembly, thetransfer wheel having an air management system, wherein the system has aconduit for the supply of air in a downward direction past thecontainers on the transfer wheel.
 2. The apparatus of claim 1 whereinthe conduit has an inlet duct adapted to be in communication with thesupply of air, the conduit further having an outlet manifold having anopening wherein the supply of air is directed through the opening. 3.The apparatus of claim 2 further comprising a mesh screen positionedover the opening.
 4. The apparatus of claim 2 wherein the outletmanifold has a curved shape.
 5. The apparatus of claim 4 wherein theoutlet manifold is positioned on a portion of the transfer wheel.
 6. Theapparatus of claim 2 wherein the outlet manifold has an open bottomsection.
 7. The apparatus of claim 2 wherein the outlet manifold has agenerally horizontal top surface wherein the opening is positioned inthe top surface.
 8. The apparatus of claim 7 wherein the outlet manifoldhas a pair of spaced sidewalls depending from the top surface.
 9. Theapparatus of claim 8 wherein a mesh screen is positioned in the openingproximate the top surface.
 10. The apparatus of claim 2 wherein theoutlet manifold has a generally inverted U-shaped cross-section.
 11. Anair management system for a transfer wheel comprising: an inlet ducthaving a plurality of diverging outlet portions, wherein the inlet ductis connected to a filtered air source and wherein the filtered airsource provides filtered air to the plurality of diverging outletportions; and an outlet manifold generally having a curved shape andgenerally having an inverted U-shaped cross section, and having a topportion having an opening in communication with the plurality ofdiverging outlet portions, and a mesh screen covering the opening,wherein the filtered air is directed through the mesh screen in adownward direction.
 12. A method for providing a local air managementsystem in a transfer wheel that conveys open containers after a fillingoperation to a capper assembly, the method comprising: providingfiltered air to the transfer wheel in a downward direction wherein thelocal air management system is adapted to direct air downwardly towardsthe containers.
 13. The method of claim 12 wherein a mesh screen isprovided wherein the filtered air passes through the mesh screen. 14.The method of claim 12 wherein the filtered air is provided on a portionof the transfer wheel.
 15. An apparatus for receiving a sterilecontainer and delivering the sterile container to a filler assembly, theapparatus comprising: a housing having a container inlet opening and acontainer outlet opening, the housing further having an air inletopening; a shroud positioned around the container inlet opening, theshroud having an open bottom end; an intake conveyor positioned in thehousing, the conveyor adapted to receive the sterile container throughthe container inlet opening and pass the sterile container to thecontainer outlet opening; and an air source in communication with theair inlet opening wherein the housing receives the air wherein the airpasses from the open bottom end.
 16. The apparatus of claim 15 whereinthe air inlet opening is positioned on a ceiling of the housing.
 17. Theapparatus of claim 15 wherein the filtered air source pressurizes thehousing.
 18. The apparatus of claim 15 wherein the air source isfiltered.
 19. The apparatus of claim 18 wherein the air source isULPA/HEPA filtered air.
 20. The apparatus of claim 15 wherein the intakeconveyor comprises an intake wheel having a gripper wherein the gripperis adapted to grip a container delivered from a container sterilizer andpass the container to the container outlet opening.
 21. The apparatus ofclaim 15 wherein the intake conveyor comprises a first intake wheeloperably associated with a second intake wheel, the first intake wheeladapted to receive the container from a container sterilizer and furtheradapted to pass the container to the second intake wheel wherein thesecond intake wheel is adapted to pass the container to the containeroutlet opening.
 22. The apparatus of claim 15 wherein the housing has anaccess door.
 23. The apparatus of claim 22 wherein the intake conveyorhas a container reject mechanism wherein unacceptable containers areremoved from the conveyor and can be accessed through the access door.24. The apparatus of claim 22 further comprising an air cylinder havingone end connected to the housing and another end connected to the accessdoor, the air cylinder being operable to open and close the access door.25. The apparatus of claim 23 wherein the housing has a floor wherein aportion of the floor is slanted towards the access door.